US20180220541A1 - Multi-Chamber GFCI Housing Apparatus - Google Patents
Multi-Chamber GFCI Housing Apparatus Download PDFInfo
- Publication number
- US20180220541A1 US20180220541A1 US15/418,733 US201715418733A US2018220541A1 US 20180220541 A1 US20180220541 A1 US 20180220541A1 US 201715418733 A US201715418733 A US 201715418733A US 2018220541 A1 US2018220541 A1 US 2018220541A1
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- Prior art keywords
- housing
- chamber
- pcb
- cover
- cable
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/66—Structural association with built-in electrical component
- H01R13/70—Structural association with built-in electrical component with built-in switch
- H01R13/713—Structural association with built-in electrical component with built-in switch the switch being a safety switch
- H01R13/7135—Structural association with built-in electrical component with built-in switch the switch being a safety switch with ground fault protector
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/0026—Casings, cabinets or drawers for electric apparatus provided with connectors and printed circuit boards [PCB], e.g. automotive electronic control units
- H05K5/0047—Casings, cabinets or drawers for electric apparatus provided with connectors and printed circuit boards [PCB], e.g. automotive electronic control units having a two-part housing enclosing a PCB
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H13/00—Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch
- H01H13/02—Details
- H01H13/04—Cases; Covers
- H01H13/06—Dustproof, splashproof, drip-proof, waterproof or flameproof casings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H13/00—Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch
- H01H13/02—Details
- H01H13/12—Movable parts; Contacts mounted thereon
- H01H13/14—Operating parts, e.g. push-button
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/28—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable
- H01R24/30—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable with additional earth or shield contacts
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/28—Clamped connections, spring connections
- H01R4/30—Clamped connections, spring connections utilising a screw or nut clamping member
- H01R4/34—Conductive members located under head of screw
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
- H01R9/22—Bases, e.g. strip, block, panel
- H01R9/24—Terminal blocks
- H01R9/2425—Structural association with built-in components
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
- H01R9/22—Bases, e.g. strip, block, panel
- H01R9/24—Terminal blocks
- H01R9/2491—Terminal blocks structurally associated with plugs or sockets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
- H02H3/00—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection
- H02H3/16—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection responsive to fault current to earth, frame or mass
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/02—Details
- H05K5/03—Covers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
- H01R13/5202—Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/66—Structural association with built-in electrical component
- H01R13/665—Structural association with built-in electrical component with built-in electronic circuit
- H01R13/6658—Structural association with built-in electrical component with built-in electronic circuit on printed circuit board
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R2103/00—Two poles
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/66—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure with pins, blades or analogous contacts and secured to apparatus or structure, e.g. to a wall
- H01R24/68—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure with pins, blades or analogous contacts and secured to apparatus or structure, e.g. to a wall mounted on directly pluggable apparatus
Definitions
- the present invention relates generally to ground fault safety devices and more specifically to circuit interrupter enclosures.
- the electrical appliance (which serves as the load of the electrical system) is connected to the power source by a pair of current-carrying wires.
- the pair of current-carrying wires typically include a hot wire and a neutral wire, the pair of wires having equal but opposite magnitudes under normal conditions.
- a ground fault condition occurs when the differential between the values of the currents of the two wires exceeds a predetermined value. Often a ground fault will occur if the hot line becomes inadvertently grounded. A ground fault condition can result in a loss of power to the electrical appliance because current is unable to flow to the load. As a consequence, an excessive amount of current tends to flow into the ground conductor of the electrical system which, in turn, creates dangerous voltage levels at points in the circuit that should be at ground potential. This condition can result in potentially dangerous electrical shocks, which could seriously injure an individual.
- ground fault safety devices are commonly employed in such electrical systems to eliminate ground fault conditions.
- One type of ground fault safety device is the ground fault circuit interrupter (GFCI).
- Another type of ground fault safety device is the appliance leakage current interrupter (ALCI).
- Ground fault circuit interrupters are used to eliminate ground fault conditions as well as grounded neutral conditions, whereas appliance leakage current interrupter are used only to eliminate ground fault conditions.
- Both types of ground fault safety devices prevent ground fault conditions from occurring by opening the electric circuit upon the detection of a ground fault condition in the pair of wires. It is known to incorporate GFCIs and ALCI's into electrical plugs, electrical switches and electrical receptacles.
- GFCIs and ALCIs are commonly mounted within a generally rectangular housing having a top, a bottom, a front end and a rear end.
- the housing is attached to the appliance by an electrical cord which extends into the housing from the rear end.
- a pair of prongs (blades) typically extend out from the housing and are sized, shaped and spaced away from each other so that they can be inserted into the sockets of an electrical outlet, thus making contact and closing the circuit.
- the electrical cord is connected inside the housing to a terminal block. Access to the terminal block often requires that the housing be disassembled to reveal the terminal block connections. However, disassembly of the housing usually exposes the GFCI or ALCI circuitry to potential damage which may not be discovered until operation, leading to potentially catastrophic damage and/or injury.
- components used to build the GFCI and ALCI circuits include discrete components (e.g., diodes, resistors, capacitors, etc), printed circuit boards (PCBs), solenoids, and relays.
- PCBs printed circuit boards
- the relative location of these components, including electrical PCB traces, is critical to prevent electrical arcing between the components.
- the housing enclosing the circuits and the terminal block is constrained in certain dimensions according to electrical codes and standards.
- the GFCI and/or ALCI circuits are susceptible to moisture damage. Consequently, there exists a need to prevent or retard moisture seepage into the circuit area. Where the terminal block and the circuitry share a common space, as in the prior art, moisture seepage into the common space may cause unknown circuitry damage to the GFCI tripping circuit and/or hardware leading to potentially catastrophic damage and/or injury.
- circuit breakers with ground fault or arc fault systems typically include a self-test button.
- These button designs usually include a mechanical spring, a secondary contact, and a hard-plastic Push to Test (PTT) button.
- the test button is typically biased by a mechanical force provided by the spring. As the test button is depressed, the mechanical spring makes contact with a secondary contact.
- the secondary contact can be made of a similar material as the mechanical spring and may have spring type properties, or the secondary contact may be a stationary pin mounted on a printed circuit board (PCB).
- PCB printed circuit board
- an electronic circuit (EC) housing is provided.
- the EC housing includes a printed circuit board (PCB) chamber and a cable chamber isolated from the PCB chamber.
- the overall length of the electronic circuit housing is less than or equal to 3.95 inches, and the volume of the PCB chamber is substantially equal to 9.25 cubic inches.
- the internal volume of the cable chamber is substantially equal to 7.35 cubic inches, and the ratio of the PCB chamber volume to the cable chamber volume is substantially constant at 1.26.
- the invention is also directed towards a water-resistant ground fault interrupter circuit (GFCI) housing.
- the housing includes a top housing cover having a length L 1 and a groove circumscribing the top housing.
- the housing also includes a bottom housing cover mateable with the top housing cover and having a length L 2 , wherein L 2 is substantially 2.2 inches.
- the bottom housing also includes a first compression ridge disposed along the top housing mating surfaces.
- the bottom housing cover also includes a second groove disposed along the bottom cable cover mating surface.
- a bottom cable cover mateable with the top housing cover and the bottom housing cover.
- the bottom cable cover also includes a second compression ridge disposed the top housing mating surfaces (i.e., the edge of the bottom cable cover that is mateable with the top housing).
- the bottom cable cover includes a third compression ridge disposed along the bottom housing mating surface.
- FIG. 1 is a perspective view of a GFCI housing according to this invention
- FIG. 1B is a perspective view of test, reset water intrusion barrier button caps and indicator lens and watertight ring;
- FIG. 2 is a side view of circuit housing shown in FIG. 1 ;
- FIG. 3 is a bottom view of a partially disassembled circuit housing shown in FIG. 1 ;
- FIG. 4 is an exploded top perspective view of the circuit housing shown in FIG. 1 ;
- FIG. 5 is an exploded bottom perspective view of the circuit housing shown in FIG. 1 ;
- FIG. 6 is a bottom view of a partially disassembled circuit housing shown in FIG. 1 ;
- FIG. 7 is an inside illustration of the top housing shown in FIG. 1 ;
- FIG. 8 is an illustration of the continuous compressible gasket shown in FIG. 7 ;
- FIG. 9 is a crosscut view taken along the line 9 - 9 in FIG. 2 ;
- FIG. 10 is an enlarged perspective view of the compression ridge, groove, and compressible gasket shown in FIG. 9 ;
- FIG. 11 is a bottom view of the housing shown in FIG. 1 , and illustrates relative dimensions.
- ком ⁇ онент or feature may,” “can,” “could,” “should,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic.
- Circuit housing 10 includes bottom PCB housing 17 , bottom cable cover 13 , and a top housing 15 . Also, shown in FIG. 1 are water intrusion barrier button caps 16 and 18 and trip indication lens 19 .
- GFCI housing 10 can be made from any suitable fire retardant material having material properties with flame ratings in accordance with Underwriters Laboratories (UL) 94 , the Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances. In one embodiment, suitable materials such as thermoplastic polyester resins based on polybutylene terephthalate (PBT) and/or polyethylene terephthalate (PET) polymers may be used.
- PBT polybutylene terephthalate
- PET polyethylene terephthalate
- FIG. 1B there is shown a perspective view of test, reset water intrusion barrier button caps 16 and 18 and indicator lens 19 and watertight ring 19 A.
- Water intrusion barrier caps 16 and 18 are flexible circular shaped membrane for fitting over a PTT button (not shown) and projecting through openings 16 O and 18 O, respectively (see FIG. 4 ).
- Barrier caps 16 and 18 include grooved circular channels 16 A, 18 A, configured to mate with circular shoulders on the underside of top housing 15 (see FIG. 5 ) to form a water-resistant seal to exclude moisture and contaminants from the housing at the openings 16 O and 18 O.
- watertight ring 19 A fits snugly over lens 19 and mates with top housing 15 to form a water-resistant seal to exclude moisture and contaminants from the housing at the opening 19 O.
- FIG. 2 there is shown a side view of circuit housing 10 shown in FIG. 1 .
- grasp ledge 21 Shown in FIG. 2 is grasp ledge 21 adapted to provide a hand grasping area and leverage for plugging and unplugging circuit housing 10 .
- height H 1 Also, referenced in FIG. 2 is height H 1 . H 1 is used in subsequent formulas for determining overall enclosed volume of circuit housing 10 .
- FIG. 3 there is shown a bottom view of a partially disassembled circuit housing 10 shown in FIG. 1 .
- cable chamber 61 electric wires or cables 31 , 33 , and 35 for conducting electricity and providing an electrical ground path.
- terminal block 17 B shown in FIG. 3 is terminal block 17 B. It will be appreciated that terminal block 17 B and PCB housing 17 are one piece.
- Terminal block 17 B provides connection 39 (only one connection is shown) for electric wires, e.g., wire 35 .
- Compressible gasket 12 may be any suitable compressible material; such as, for example, natural rubber, silicon rubber, urethane rubber, latex, neoprene, and other similar materials.
- FIG. 4 there is shown an exploded top perspective view of the circuit housing 10 shown in FIG. 1 .
- Shown in FIG. 4 is a top view of top housing 15 , reset and test openings, 16 O, 18 O, respectively, and lens opening 19 O; the inner underside of PCB housing 17 ; compression ridge 17 C for compressing a portion of compression gasket 12 when PCB housing 17 is mated with top housing 15 , PCB housing mating face 17 A for mating with cable housing mating face 13 A, the inner underside of cable housing 13 , cable housing compression ridge 43 for mating with PCB housing groove 41 and compressing a portion of compression gasket 12 (see FIG. 3 , FIG.
- compression ridge 10 B for compressing another portion of compression gasket 12 when the cable housing 13 is mated with top housing 15 . Also, shown in FIG. 4 is ride wall 13 B which demarks one side of the cable chamber (see FIG. 6 , item 61 ).
- FIG. 5 there is shown an exploded bottom perspective view of the circuit housing 10 shown in FIG. 1 .
- Shown in FIG. 5 is a top view of PCB housing 17 , PCB housing mating face 17 A for mating with cable housing mating face 13 A (see FIG. 4-13A ), integrated terminal block 17 B (i.e., terminal block 17 B is a one piece with PCB housing 17 ), and a top view of cable housing 13 .
- FIG. 5 is perspective view of the inner underside of top housing 15 ; an underside view of water intrusion barrier caps 16 and 18 in place flush against the inner underside of top housing 15 , and lens 19 and watertight ring 19 A, flush against the inner underside 62 of top housing 15 .
- Also shown in FIG. 5 is a portion of compression gasket 12 within top housing groove 51 circumscribing the top housing 15 .
- FIG. 6 there is shown a bottom view of a partially disassembled circuit housing 10 shown in FIG. 1 .
- Shown in FIG. 6 is perspective view of the inner underside 62 of top housing 15 ; an underside view of water intrusion barrier caps 16 and 18 in place flush against the inner underside of top housing 15 , and lens 19 and watertight ring 19 A, flush against the inner underside 62 of top housing 15 .
- cable chamber 61 formed by mating cable chamber housing 13 with top housing 15 .
- FIG. 6 is a portion of compression gasket 12 within top housing groove 51 circumscribing the top housing 15 .
- FIG. 7 there is shown an inside illustration 62 of the top housing 15 shown in FIG. 1 . Shown in FIG. 7 is compressible gasket 12 circumscribing top housing 15 within groove 51 circumscribing top housing 15 . Also shown is transverse compressible gasket 12 B, joined to compressible gasket 12 at joints 12 C and 12 D. It will be appreciated that compressible gasket 12 and transverse compressible gasket 12 B are one piece as shown in FIG. 8 . It will be understood that transverse compressible gasket 12 B fits within PCB housing groove 41 (see FIG. 3 and/or FIG. 4 ).
- FIG. 9 there is shown a crosscut view taken along the line 9 - 9 in FIG. 2 . Shown in FIG. 9 is cable chamber housing 13 mated with top housing 15 . Compressing ridge 10 B compresses compression gasket 12 in channel 51 forming a water-resistant barrier. Referring also to FIG. 10 there is shown an enlarged perspective view of the compression ridge 10 B, groove 51 , and compressible gasket 12 shown in FIG. 9 .
- FIG. 11 there is shown a bottom view of the housing 10 shown in FIG. 1 , and illustrates relative dimensions.
- the overall length L of the electronic circuit housing 10 is less than or equal to 3.95 inches, and the volume of the PCB chamber defined by L 2 , W 1 , and H 1 (shown in FIG. 2 ) is substantially equal to 9.25 cubic inches.
- the internal volume of the cable chamber ( FIG. 6-61 ) is substantially equal to 7.35 cubic inches, and the ratio of the PCB chamber volume to the cable chamber volume is substantially constant at 1.26.
- isolating the cable chamber from the PCB chamber and holding the volume of each chamber constant provides sufficient housing volume to allow for sufficient spacing between electrical components (not shown) and electrical PCB traces (not shown) to prevent the risk of arcing between the components while also adhering to certain constrained dimensions according to electrical codes and standards; such as, for example UL 943 Ground Fault Circuit Interrupters, and UL 840 Insulation Coordination Including Clearances and Creepage Distances for Electrical Equipment, both incorporated by reference in their entirety.
- the PCB housing cover 17 L 2 is substantially 2.2 inches.
- the bottom cable cover 13 length L 3 wherein L 3 is less than or equal to 1.75 inches.
- L 2 +L 3 L 1 .
Abstract
Description
- The present invention relates generally to ground fault safety devices and more specifically to circuit interrupter enclosures.
- It is well known for electrical appliances, such as hair dryers, to draw electrical power through connection to a power source, such as an electrical outlet. Specifically, the electrical appliance (which serves as the load of the electrical system) is connected to the power source by a pair of current-carrying wires. The pair of current-carrying wires typically include a hot wire and a neutral wire, the pair of wires having equal but opposite magnitudes under normal conditions.
- On occasion, the electrical system may experience a ground fault condition while the load is connected to the power supply. A ground fault condition occurs when the differential between the values of the currents of the two wires exceeds a predetermined value. Often a ground fault will occur if the hot line becomes inadvertently grounded. A ground fault condition can result in a loss of power to the electrical appliance because current is unable to flow to the load. As a consequence, an excessive amount of current tends to flow into the ground conductor of the electrical system which, in turn, creates dangerous voltage levels at points in the circuit that should be at ground potential. This condition can result in potentially dangerous electrical shocks, which could seriously injure an individual.
- Accordingly, ground fault safety devices are commonly employed in such electrical systems to eliminate ground fault conditions. One type of ground fault safety device is the ground fault circuit interrupter (GFCI). Another type of ground fault safety device is the appliance leakage current interrupter (ALCI). Ground fault circuit interrupters are used to eliminate ground fault conditions as well as grounded neutral conditions, whereas appliance leakage current interrupter are used only to eliminate ground fault conditions.
- Both types of ground fault safety devices prevent ground fault conditions from occurring by opening the electric circuit upon the detection of a ground fault condition in the pair of wires. It is known to incorporate GFCIs and ALCI's into electrical plugs, electrical switches and electrical receptacles.
- GFCIs and ALCIs are commonly mounted within a generally rectangular housing having a top, a bottom, a front end and a rear end. The housing is attached to the appliance by an electrical cord which extends into the housing from the rear end. A pair of prongs (blades) typically extend out from the housing and are sized, shaped and spaced away from each other so that they can be inserted into the sockets of an electrical outlet, thus making contact and closing the circuit.
- The electrical cord is connected inside the housing to a terminal block. Access to the terminal block often requires that the housing be disassembled to reveal the terminal block connections. However, disassembly of the housing usually exposes the GFCI or ALCI circuitry to potential damage which may not be discovered until operation, leading to potentially catastrophic damage and/or injury.
- Furthermore, components used to build the GFCI and ALCI circuits include discrete components (e.g., diodes, resistors, capacitors, etc), printed circuit boards (PCBs), solenoids, and relays. The relative location of these components, including electrical PCB traces, is critical to prevent electrical arcing between the components. Thus, there must be sufficient housing volume to allow for sufficient spacing between components and electrical PCB traces to prevent the risk of arcing between the components. However, the housing enclosing the circuits and the terminal block is constrained in certain dimensions according to electrical codes and standards.
- Furthermore, the GFCI and/or ALCI circuits are susceptible to moisture damage. Consequently, there exists a need to prevent or retard moisture seepage into the circuit area. Where the terminal block and the circuitry share a common space, as in the prior art, moisture seepage into the common space may cause unknown circuitry damage to the GFCI tripping circuit and/or hardware leading to potentially catastrophic damage and/or injury.
- Similarly, circuit breakers with ground fault or arc fault systems typically include a self-test button. These button designs usually include a mechanical spring, a secondary contact, and a hard-plastic Push to Test (PTT) button. The test button is typically biased by a mechanical force provided by the spring. As the test button is depressed, the mechanical spring makes contact with a secondary contact. The secondary contact can be made of a similar material as the mechanical spring and may have spring type properties, or the secondary contact may be a stationary pin mounted on a printed circuit board (PCB).
- One disadvantage is that a gap between the test button and a housing of the circuit breaker is present before or during when the button is depressed. When the gap between the button and the housing is present, several concerns arise related to moisture, corrosion, and potential electric shock. With the gap present, internal components are exposed to outside moisture and/or other containments that could disable the tripping functions of the test button. Although PCB's are typically conformal coated, this does not guarantee that moisture could not damage the PCB and/or related electrical components and disable the push to test button and/or present the possibility of the a user being exposed to electrical shock.
- The foregoing and other problems are overcome, and other advantages are realized, in accordance with the presently preferred embodiments of these teachings.
- In accordance with one embodiment of the present invention an electronic circuit (EC) housing is provided. The EC housing includes a printed circuit board (PCB) chamber and a cable chamber isolated from the PCB chamber. The overall length of the electronic circuit housing is less than or equal to 3.95 inches, and the volume of the PCB chamber is substantially equal to 9.25 cubic inches. The internal volume of the cable chamber is substantially equal to 7.35 cubic inches, and the ratio of the PCB chamber volume to the cable chamber volume is substantially constant at 1.26.
- The invention is also directed towards a water-resistant ground fault interrupter circuit (GFCI) housing. The housing includes a top housing cover having a length L1 and a groove circumscribing the top housing. The housing also includes a bottom housing cover mateable with the top housing cover and having a length L2, wherein L2 is substantially 2.2 inches. The bottom housing also includes a first compression ridge disposed along the top housing mating surfaces. The bottom housing cover also includes a second groove disposed along the bottom cable cover mating surface. Also included is a bottom cable cover mateable with the top housing cover and the bottom housing cover. The bottom cable cover has a length L3, wherein L3 is less than or equal to 1.75 inches. Overall, L2+L3=L1. The bottom cable cover also includes a second compression ridge disposed the top housing mating surfaces (i.e., the edge of the bottom cable cover that is mateable with the top housing). The bottom cable cover includes a third compression ridge disposed along the bottom housing mating surface.
- Various other features and advantages will appear from the description to follow. In the description, reference is made to the accompanying drawings which form a part thereof, and in which is shown by way of illustration, specific embodiments for practicing the invention. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. The following detailed description is therefore, not to be taken in a limiting sense.
- The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
-
FIG. 1 is a perspective view of a GFCI housing according to this invention; -
FIG. 1B is a perspective view of test, reset water intrusion barrier button caps and indicator lens and watertight ring; -
FIG. 2 is a side view of circuit housing shown inFIG. 1 ; -
FIG. 3 is a bottom view of a partially disassembled circuit housing shown inFIG. 1 ; -
FIG. 4 is an exploded top perspective view of the circuit housing shown inFIG. 1 ; -
FIG. 5 is an exploded bottom perspective view of the circuit housing shown inFIG. 1 ; -
FIG. 6 is a bottom view of a partially disassembled circuit housing shown inFIG. 1 ; -
FIG. 7 is an inside illustration of the top housing shown inFIG. 1 ; -
FIG. 8 is an illustration of the continuous compressible gasket shown inFIG. 7 ; -
FIG. 9 is a crosscut view taken along the line 9-9 inFIG. 2 ; -
FIG. 10 is an enlarged perspective view of the compression ridge, groove, and compressible gasket shown inFIG. 9 ; and -
FIG. 11 is a bottom view of the housing shown inFIG. 1 , and illustrates relative dimensions. - The following brief definition of terms shall apply throughout the application:
- The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;
- The phrases “in one embodiment,” “according to one embodiment,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);
- If the specification describes something as “exemplary” or an “example,” it should be understood that refers to a non-exclusive example; and
- If the specification states a component or feature “may,” “can,” “could,” “should,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic.
- Referring now to
FIG. 1 there is shown is a perspective view of acircuit housing 10 according to this invention.Circuit housing 10 includesbottom PCB housing 17,bottom cable cover 13, and atop housing 15. Also, shown inFIG. 1 are water intrusion barrier button caps 16 and 18 andtrip indication lens 19.GFCI housing 10 can be made from any suitable fire retardant material having material properties with flame ratings in accordance with Underwriters Laboratories (UL) 94, the Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances. In one embodiment, suitable materials such as thermoplastic polyester resins based on polybutylene terephthalate (PBT) and/or polyethylene terephthalate (PET) polymers may be used. - Referring also to
FIG. 1B there is shown a perspective view of test, reset water intrusion barrier button caps 16 and 18 andindicator lens 19 andwatertight ring 19A. Water intrusion barrier caps 16 and 18 are flexible circular shaped membrane for fitting over a PTT button (not shown) and projecting through openings 16O and 18O, respectively (seeFIG. 4 ). Barrier caps 16 and 18 include groovedcircular channels FIG. 5 ) to form a water-resistant seal to exclude moisture and contaminants from the housing at the openings 16O and 18O. - Still referring to
FIG. 1B , there is shownwatertight ring 19A.Watertight ring 19A fits snugly overlens 19 and mates withtop housing 15 to form a water-resistant seal to exclude moisture and contaminants from the housing at the opening 19O. - Referring also to
FIG. 2 there is shown a side view ofcircuit housing 10 shown inFIG. 1 . Shown inFIG. 2 isgrasp ledge 21 adapted to provide a hand grasping area and leverage for plugging and unpluggingcircuit housing 10. Also, referenced inFIG. 2 is height H1. H1 is used in subsequent formulas for determining overall enclosed volume ofcircuit housing 10. - Referring also to
FIG. 3 there is shown a bottom view of a partially disassembledcircuit housing 10 shown inFIG. 1 . Shown inFIG. 3 iscable chamber 61; electric wires orcables FIG. 3 isterminal block 17B. It will be appreciated thatterminal block 17B andPCB housing 17 are one piece.Terminal block 17B provides connection 39 (only one connection is shown) for electric wires, e.g., wire 35. - Still referring to
FIG. 3 there is shown a portion of thecompressible gasket 12.Compressible gasket 12 may be any suitable compressible material; such as, for example, natural rubber, silicon rubber, urethane rubber, latex, neoprene, and other similar materials. - Referring also to
FIG. 4 there is shown an exploded top perspective view of thecircuit housing 10 shown inFIG. 1 . Shown inFIG. 4 is a top view oftop housing 15, reset and test openings, 16O, 18O, respectively, and lens opening 19O; the inner underside ofPCB housing 17;compression ridge 17C for compressing a portion ofcompression gasket 12 whenPCB housing 17 is mated withtop housing 15, PCBhousing mating face 17A for mating with cablehousing mating face 13A, the inner underside ofcable housing 13, cablehousing compression ridge 43 for mating withPCB housing groove 41 and compressing a portion of compression gasket 12 (seeFIG. 3 ,FIG. 5 ); andcompression ridge 10B for compressing another portion ofcompression gasket 12 when thecable housing 13 is mated withtop housing 15. Also, shown inFIG. 4 is ride wall 13B which demarks one side of the cable chamber (seeFIG. 6 , item 61). - Referring also to
FIG. 5 there is shown an exploded bottom perspective view of thecircuit housing 10 shown inFIG. 1 . Shown inFIG. 5 is a top view ofPCB housing 17, PCBhousing mating face 17A for mating with cablehousing mating face 13A (seeFIG. 4-13A ), integratedterminal block 17B (i.e.,terminal block 17B is a one piece with PCB housing 17), and a top view ofcable housing 13. Also, shown inFIG. 5 is perspective view of the inner underside oftop housing 15; an underside view of water intrusion barrier caps 16 and 18 in place flush against the inner underside oftop housing 15, andlens 19 andwatertight ring 19A, flush against theinner underside 62 oftop housing 15. Also shown inFIG. 5 is a portion ofcompression gasket 12 withintop housing groove 51 circumscribing thetop housing 15. - Referring also to
FIG. 6 there is shown a bottom view of a partially disassembledcircuit housing 10 shown inFIG. 1 . Shown inFIG. 6 is perspective view of theinner underside 62 oftop housing 15; an underside view of water intrusion barrier caps 16 and 18 in place flush against the inner underside oftop housing 15, andlens 19 andwatertight ring 19A, flush against theinner underside 62 oftop housing 15. Also, shown inFIG. 6 iscable chamber 61 formed by matingcable chamber housing 13 withtop housing 15. Also, shown inFIG. 6 is a portion ofcompression gasket 12 withintop housing groove 51 circumscribing thetop housing 15. - Referring also to
FIG. 7 there is shown aninside illustration 62 of thetop housing 15 shown inFIG. 1 . Shown inFIG. 7 iscompressible gasket 12 circumscribingtop housing 15 withingroove 51 circumscribingtop housing 15. Also shown is transversecompressible gasket 12B, joined tocompressible gasket 12 atjoints compressible gasket 12 and transversecompressible gasket 12B are one piece as shown inFIG. 8 . It will be understood that transversecompressible gasket 12B fits within PCB housing groove 41 (seeFIG. 3 and/orFIG. 4 ). - Referring also to
FIG. 9 there is shown a crosscut view taken along the line 9-9 inFIG. 2 . Shown inFIG. 9 iscable chamber housing 13 mated withtop housing 15. Compressingridge 10B compressescompression gasket 12 inchannel 51 forming a water-resistant barrier. Referring also toFIG. 10 there is shown an enlarged perspective view of thecompression ridge 10B,groove 51, andcompressible gasket 12 shown inFIG. 9 . - Referring also to
FIG. 11 there is shown a bottom view of thehousing 10 shown inFIG. 1 , and illustrates relative dimensions. The overall length L of theelectronic circuit housing 10 is less than or equal to 3.95 inches, and the volume of the PCB chamber defined by L2, W1, and H1 (shown inFIG. 2 ) is substantially equal to 9.25 cubic inches. The internal volume of the cable chamber (FIG. 6-61 ) is substantially equal to 7.35 cubic inches, and the ratio of the PCB chamber volume to the cable chamber volume is substantially constant at 1.26. It will be appreciated that isolating the cable chamber from the PCB chamber and holding the volume of each chamber constant provides sufficient housing volume to allow for sufficient spacing between electrical components (not shown) and electrical PCB traces (not shown) to prevent the risk of arcing between the components while also adhering to certain constrained dimensions according to electrical codes and standards; such as, for example UL 943 Ground Fault Circuit Interrupters, and UL 840 Insulation Coordination Including Clearances and Creepage Distances for Electrical Equipment, both incorporated by reference in their entirety. - Still referring to
FIG. 11 , in one embodiment, thePCB housing cover 17 L2 is substantially 2.2 inches. Thebottom cable cover 13 length L3, wherein L3 is less than or equal to 1.75 inches. Overall, L2+L3=L1. - It should be understood that the foregoing description is only illustrative of the invention. Thus, various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims.
Claims (15)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/418,733 US20180220541A1 (en) | 2017-01-29 | 2017-01-29 | Multi-Chamber GFCI Housing Apparatus |
CN201820140439.8U CN208189484U (en) | 2017-01-29 | 2018-01-26 | Earth-fault current relay |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/418,733 US20180220541A1 (en) | 2017-01-29 | 2017-01-29 | Multi-Chamber GFCI Housing Apparatus |
Publications (1)
Publication Number | Publication Date |
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US20180220541A1 true US20180220541A1 (en) | 2018-08-02 |
Family
ID=62980503
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US15/418,733 Abandoned US20180220541A1 (en) | 2017-01-29 | 2017-01-29 | Multi-Chamber GFCI Housing Apparatus |
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US (1) | US20180220541A1 (en) |
CN (1) | CN208189484U (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10326264B1 (en) * | 2018-04-25 | 2019-06-18 | Schneider Electric USA, Inc. | Auto-monitoring redundancy for enhanced miniature circuit breaker reliability |
USD860138S1 (en) * | 2018-09-30 | 2019-09-17 | Tower Manufacturing Corp. | Outdoor plug |
USD868698S1 (en) * | 2017-04-16 | 2019-12-03 | Tower Manufacturing Corp. | Arc fault circuit interrupter outlet adapter |
USD872035S1 (en) * | 2016-11-08 | 2020-01-07 | Tower Manufacturing Corp. | Arc fault circuit interrupter |
USD880426S1 (en) * | 2017-04-16 | 2020-04-07 | Tower Manufacturing Corporation | Arc fault current interrupter |
US11300617B2 (en) * | 2018-08-02 | 2022-04-12 | Semiconductor Components Industries, Llc | Ground fault interrupter self test circuits and related methods |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN111384606A (en) * | 2018-12-28 | 2020-07-07 | 漳州市龙文区中豪照明科技有限公司 | Plug connector of illuminating lamp |
-
2017
- 2017-01-29 US US15/418,733 patent/US20180220541A1/en not_active Abandoned
-
2018
- 2018-01-26 CN CN201820140439.8U patent/CN208189484U/en active Active
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
USD872035S1 (en) * | 2016-11-08 | 2020-01-07 | Tower Manufacturing Corp. | Arc fault circuit interrupter |
USD868698S1 (en) * | 2017-04-16 | 2019-12-03 | Tower Manufacturing Corp. | Arc fault circuit interrupter outlet adapter |
USD880426S1 (en) * | 2017-04-16 | 2020-04-07 | Tower Manufacturing Corporation | Arc fault current interrupter |
US10326264B1 (en) * | 2018-04-25 | 2019-06-18 | Schneider Electric USA, Inc. | Auto-monitoring redundancy for enhanced miniature circuit breaker reliability |
US11300617B2 (en) * | 2018-08-02 | 2022-04-12 | Semiconductor Components Industries, Llc | Ground fault interrupter self test circuits and related methods |
US11668752B2 (en) | 2018-08-02 | 2023-06-06 | Semiconductor Components Industries, Llc | Ground fault interrupter self test circuits and related methods |
USD860138S1 (en) * | 2018-09-30 | 2019-09-17 | Tower Manufacturing Corp. | Outdoor plug |
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CN208189484U (en) | 2018-12-04 |
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